DE102020206416A1 - Cooling device for a connector element and connector element for high-voltage applications - Google Patents

Abstract

The present invention relates to a cooling device for a connector element and an associated connector element for high-voltage (HV) applications. The invention also relates to a method for installing a high-voltage connector element. The cooling device (114) comprises a cooling channel through which a cooling fluid (126) can flow during operation, and a bearing element (122) which holds the cooling channel, the cooling channel being a component that is separate from the bearing element and having the shape of at least one hollow pipe ( 120) which engages around the bearing element (122) at least in part of a circumference of the bearing element (122).

Description

The present invention relates to a cooling device for a connector element and an associated connector element for high-voltage (HV) applications. The invention also relates to a method for installing a high-voltage connector element.

In electromobility, high-voltage connectors with large cable cross-sections are required to drive and charge the high-voltage battery. In order to shorten the charging times or to get the required power from a battery, high electrical current densities are sometimes required in the HV system. As a result, the temperature in a connector can increase impermissibly under unfavorable conditions. However, reaching the maximum allowable temperature limits the energy that can be transferred. Passive cooling and the provision of sufficiently large cable cross-sections can help, but usually leads to undesirably large dimensions of the connector and high material costs.

Active cooling with the aid of a cooling fluid, for example a cooling liquid, is therefore advantageous. Known connector elements with integrated cooling channels, however, have the disadvantage that, on the one hand, they are not suitable for retrofitting existing connector systems and, on the other hand, are complex, difficult-to-manufacture components.

There is therefore a need for a cooling device for a connector element and an associated connector element which overcome the disadvantages of the known solutions so that the connector elements produced are safe and reliable, but can still be produced inexpensively and take up little space.

This object is achieved by the subject matter of the independent claims. Advantageous embodiments of the present invention are the subject of the dependent claims.

The present invention is based on the idea of achieving active cooling with minimal additional space requirements by providing a separate hollow line through which a cooling fluid can flow during operation and is attached to the connector element. The hollow line, which is also referred to below as a cooling line and forms a cooling channel, is advantageously placed in the vicinity of the contacting point (also referred to as a “hotspot” below). The cooling fluid, e.g. B. a cooling liquid, as it is already present in the motor vehicle, absorbs the heat generated in the connector and transports it to a corresponding heat sink. As a result, particularly efficient heat management and consequently efficient energy transfer can be achieved without increasing installation space and costs.

In particular, a cooling device for a connector element comprises a cooling channel through which a cooling fluid can flow during operation, and a bearing element that holds the cooling channel, wherein the cooling channel is a component separate from the bearing element and has the shape of at least one hollow line, which at least the bearing element engages in part of a circumference of the bearing element. Such a hollow line is designed, for example, as a hose or pipe and placed as close as possible to the hotspot around the connector element.

The hollow line can wrap around only part of the circumference of the cooling device connector element or it can be guided in several turns around the bearing element and thus around the circumference of the connector element. If the hollow line engages around the bearing element in a large number of turns, heat dissipation is improved because a larger area of the connector element can be in heat-conducting connection with the cooling fluid. Furthermore, several separate hollow lines can also be run in parallel.

According to an advantageous embodiment, the hollow line has an electrically conductive material. For example, the hollow pipe can be a metallic material such as. B. have copper and optionally have further coatings. Metallic materials have the advantage of particularly efficient heat transfer between the connector element and the cooling fluid.

In order to ensure electrical insulation between the plug connector element and the hollow line, it can be provided that the bearing element is made at least partially from an electrically insulating material. This is particularly advantageous when the hollow pipe is a metallic material such as. B. comprises copper and the cooling fluid is electrically conductive. For example, the bearing element can be formed by a plastic sleeve which is pushed onto the connector element.

According to an advantageous development of the present invention, it can be provided that the bearing element is designed as an integral part of a base body of the connector element. The cooling line is z. B. wound directly around the contact body for medium cooling capacities. In particular if the base body is an electrically conductive part of the connector element, such as. B. is a contact socket, has this configuration the advantage that a particularly efficient heat dissipation can be ensured in a particularly simple and space-saving manner. Then the hollow pipe should not conduct electricity.

In particular, if the bearing element is at least partially electrically conductive, it is advantageous to produce the hollow line from an electrically insulating, but nevertheless as good as possible thermally conductive material.

According to an advantageous development of the present invention, it can be provided that the bearing element has a tubular shape and the hollow line, which forms the cooling channel, is held in a radially circumferential groove. As a result, a secure hold of the hollow pipe can be ensured even under rough environmental conditions such as vibrations and strong temperature fluctuations.

Depending on whether electrically insulating properties are required, the hollow line can be made at least partially from copper or silicone, for example. Of course, all other materials suitable for the production of a separate cooling line such as polytetrafluoroethylene (PTFE), polyethylene (PE) or polypropylene (PP) can also be used. Of course, there are also composite hoses, which, for. B. are reinforced by deposits of metal, fiberglass or textile braids, in question.

The advantages of a cooling device according to the present invention come into play particularly when it is used in a connector element with an electrically conductive base body, the bearing element at least partially surrounding the base body so that the cooling channel is in a thermally conductive connection with the base body. The base body can, for example, be a contact element of the connector element, e.g. B. be a socket element.

The present invention also provides a connector system with a first connector element and a matching second connector element, wherein the first and the second connector element can be connected to one another in an electrically conductive manner and at least one of the connector elements has a cooling device according to the present invention.

• Bereitstellen eines Grundkörpers mit einem Lagerelement; Anbringen eines Kühlkanals, der von dem Lagerelement gehalten wird, wobei der Kühlkanal ein von dem Lagerelement getrenntes Bauteil ist und die Gestalt einer Hohlleitung hat, welche das Lagerelement wenigstens in einem Teil eines Umfangs des Lagerelements umgreift.

The present invention also relates to a method for installing a high-voltage connector element, the method having the following steps:

• Providing a base body with a bearing element; Attaching a cooling channel which is held by the bearing element, the cooling channel being a component separate from the bearing element and having the shape of a hollow conduit which surrounds the bearing element at least in part of a circumference of the bearing element.

Existing high-voltage connector elements can be retrofitted particularly easily if the bearing element has a sleeve-shaped sleeve, which can also be referred to as an adapter, and which is pushed onto the base body. This cuff can also fulfill an electrically insulating function if the base body is an electrically conductive contact element of the high-voltage connector element and the hollow pipe is also made of an electrically conductive material, such as. B. copper.

Alternatively, it can also be provided that the bearing element is formed by a receptacle which is designed as an integral part of the base body of the connector element. This embodiment has the advantage of a particularly small size and optimal heat dissipation.

Existing connector elements can be retrofitted particularly easily if the step of attaching the cooling channel comprises winding around the bearing element with at least one turn of the hollow line.

The active cooling according to the invention advantageously uses a cooling circuit provided in the higher-level unit in which the connector element is located. The method then further comprises the step of connecting the hollow pipe to a cooling circuit, e.g. B. a motor vehicle or at a charging station. The cooling solution can also simply work on the principle of a heat pipe and provide that the closed, coolant-filled hollow pipe ends at a heat sink, so that the coolant evaporates on the connector element and again on the heat sink, which acts as a heat sink condensed.

• 1 eine schematische Schnittdarstellung eines Hochvoltsteckverbindersystems gemäß einem ersten Beispiel;
• 2 eine schematische perspektivische Darstellung des Hochvoltsteckverbindersystems gemäß dem ersten Beispiel;
• 3 eine schematische Explosionsdarstellung des Hochvoltsteckverbindersystems gemäß dem ersten Beispiel;
• 4 eine schematische Schnittdarstellung eines Hochvoltsteckverbindersystems gemäß einem zweiten Beispiel;
• 5 eine schematische perspektivische Darstellung des Hochvoltsteckverbindersystems gemäß dem zweiten Beispiel;
• 6 eine schematische Schnittdarstellung eines Hochvoltsteckverbindersystems gemäß einem dritten Beispiel;
• 7 eine schematische perspektivische Darstellung des Hochvoltsteckverbindersystems gemäß dem dritten Beispiel.

For a better understanding of the present invention, it is explained in more detail with reference to the exemplary embodiments shown in the following figures. The same parts are provided with the same reference numerals and the same component names. Furthermore, some features or combinations of features from the different embodiments shown and described can represent in themselves independent, inventive or inventive solutions. Show it:

• 1 a schematic sectional illustration of a high-voltage connector system according to a first example;
• 2 a schematic perspective illustration of the high-voltage connector system according to the first example;
• 3 a schematic exploded view of the high-voltage connector system according to the first example;
• 4th a schematic sectional view of a high-voltage connector system according to a second example;
• 5 a schematic perspective illustration of the high-voltage connector system according to the second example;
• 6th a schematic sectional illustration of a high-voltage connector system according to a third example;
• 7th a schematic perspective illustration of the high-voltage connector system according to the third example.

The present invention is explained below with reference to the figures, and in particular initially with reference to the schematic sectional illustration of FIG 1 and the perspective view of FIG 2 , explained in more detail. It is noted that in all of the figures the size ratios and in particular the layer thickness ratios are not necessarily shown true to scale. Furthermore, parts that are not necessary or obstructive for understanding are not shown, in particular electrically insulating housing elements and protective covers.

The figures explain an example of an active cooling solution that is used in a high-voltage (HV) round plug (e.g. with a diameter of 12 mm). Other connector geometries can of course also be designed with a cooling device according to the principles of the present invention. Furthermore, the cooling device can also be provided on both connector elements or only on the second connector element, although this is not shown in the figures. In other words, the cooling device does not necessarily have to be (only) associated with the socket element.

1 shows a connector system in the form of a sectional view 100 according to a first advantageous embodiment of the present invention. 2 shows the corresponding perspective view of the connector system 100 according to the first embodiment.

The connector system 100 has a first connector element 102 on, which is designed as a socket element. The first connector element 102 is like in 1 shown in a housing element 132 assembled. Furthermore, the connector system 100 a second connector element 104 on, which can also be referred to as a mating connector element. The second connector element 104 has an electrically conductive pin-shaped contact unit 128 on, which is in the socket-shaped body 118 of the first connector element is immersed. In the assembled state, which is shown here, can have a contact area 108 electric current, as indicated by the arrows 106 symbolizes, flow. Usually the main body is 118 connected to a busbar, which is in the lower part of the base body of the 1 is arranged (not shown) to receive the power.

The second connector element 104 is in the assembled state in the contact area 108 to the main body 118 pressed. This allows a current flow (current arrows 106 ) between the electrically conductive second connector element 104 in the main body 118 of the first connector element 102 take place.

In order to prevent the live parts of the first connector element from being plugged together 102 can be touched is on the first connector element 102 a contact protection element 116 arranged. The contact protection element 116 is made of an electrically non-conductive material. In cooperation with a plastic housing (not visible in the figure), the contact protection element prevents 116 that objects that have larger dimensions than a defined test finger can come into contact with the live parts.

According to the present invention, the connector system comprises 100 a cooling device 114 for the removal of heat that is generated when an electrical current flows.

In particular, the cooling device 114 a cooling channel through a hollow pipe 120 is formed. The hollow pipe 120 is in a bearing element 122 held. This is the bearing element 122 according to the 1 until 3 The embodiment shown is a plastic sleeve that has a groove 124 to hold the hollow pipe 120 having.

How to continue from 2 becomes clear, the hollow pipe can 120 of a coolant 126 are flowed through. For example, it can be a cooling fluid, and in particular a Act coolant. Due to the heat-conducting contact of the hollow pipe 120 with the main body 118 at a relatively small distance from the contact area 108 can do that through the hollow pipe 120 guided coolant 126 efficiently transport the heat generated. The cooling fluid can 126 for example, be connected to the coolant circuit of a motor vehicle.

In the embodiment shown, it is made possible by the bearing element made from an insulating material 122 , an electrical insulation between the hollow pipe 120 and the main body 118 of the first connector element 102 to ensure. It is therefore not necessary that the material of the hollow pipe 120 is electrically insulating. For example, the hollow pipe 120 can be made from a metal such as copper. This has the advantage of particularly good heat conduction. In addition, a copper pipe is comparatively stable and robust even under adverse environmental conditions.

3 shows an exploded view of the connector system 100 according to the first example. As is clear from this view, the bearing element can be used for assembly of the arrangement 122 in the axial direction on the base body 118 be postponed. The hollow pipe 120 can be placed in the groove before mounting on the base body or afterwards 124 be inserted. Here is the cooling device 114 in one area 130 arranged with a reduced cross-section. This ensures that the installation space required in the radial direction can be kept as small as possible.

In the case of the 1 until 3 The embodiment shown is the hollow pipe 102 only in a single turn around the bearing element 122 shown around. This variant has the advantage that the hollow pipe 120 can be easily installed and requires little additional space in the axial direction.

If, on the other hand, a larger heat-conducting contact surface is to be provided between the hollow line and the first connector element, it can also be provided that the hollow line surrounds the bearing element in several turns. An example of such a solution is in the 4th and 5 illustrated.

4th shows a connector system in the form of a sectional view 200 according to a second advantageous embodiment of the present invention. 5 shows the corresponding perspective view of the connector system 200 according to the second embodiment.

The connector system 200 has a first connector element 202 on, which is designed as a socket element. The first connector element 202 is mounted in a power rail (not visible in the figures). Furthermore, the connector system 200 a second connector element 204 on, which can also be referred to as a mating connector element. In the assembled state, which is shown here, can have a contact area 208 electric current flow.

The first connector element 202 has an electrically conductive base body 218 on. The second connector element 204 is in the assembled state in the contact area 208 on the inner wall of the base body 218 pressed. This allows a current to flow between the electrically conductive second connector element 204 in the main body 218 of the first connector element 202 take place.

In order to prevent the live parts of the first connector element from being plugged together 202 can be touched is on the first connector element 202 a contact protection element 216 arranged. The contact protection element 216 is made of an electrically non-conductive material. In cooperation with a plastic housing (not visible in the figure), the contact protection element prevents 216 that objects that have larger dimensions than a defined test finger can come into contact with the live parts.

According to the present invention, the connector system comprises 200 a cooling device 214 for the removal of heat that is generated when an electrical current flows.

In particular, the cooling device 214 a cooling channel through a hollow pipe 220 is formed. The hollow pipe 220 is in a bearing element 222 held. This is the bearing element 222 according to the 4th and 5 The embodiment shown is a plastic sleeve that has a groove 224 to hold the hollow pipe 220 having. The groove 224 extends in the axial direction far enough that the hollow pipe 220 several times around the bearing element 222 can be wound. This creates the thermally conductive transition between the base body 218 and the cooling duct is enlarged compared to the first embodiment, thereby increasing the heat dissipation efficiency.

As well as with regard to the 1 until 3 is described, the hollow pipe 220 a coolant flows through it during operation. For example, it can be a cooling fluid, and in particular a cooling liquid. Due to the heat-conducting contact of the hollow pipe 220 with the main body 218 at a relatively small distance from that Contact area 208 can do that through the hollow pipe 220 guided coolants efficiently remove the heat generated. The cooling fluid can for example be connected to the cooling fluid circuit of a motor vehicle.

In the second embodiment shown, it is also made possible by the bearing element made from an insulating material 222 , an electrical insulation between the hollow pipe 220 and the main body 218 of the first connector element 202 to ensure. It is therefore not necessary that the material of the hollow pipe 220 is electrically insulating. For example, the hollow pipe 220 can be made from a metal such as copper. This has the advantage of particularly good heat conduction. In addition, a copper pipe is comparatively stable and robust even under adverse environmental conditions.

If, on the other hand, an electrically insulating (but nevertheless as good as possible thermally conductive) material is used for the hollow line, the bearing element can also be designed as an integral part of the electrically conductive base body of the first connector element. An example of such a third embodiment is shown in FIGS 6th and 7th shown.

6th shows a connector system in the form of a sectional view 300 according to a third advantageous embodiment of the present invention. 7th shows the corresponding perspective view of the connector system 300 according to the third embodiment.

The connector system 300 has a first connector element 302 on, which is designed as a socket element. The first connector element 302 is mounted in a power rail (not visible in the figures). Furthermore, the connector system 300 a second connector element 304 on, which can also be referred to as a mating connector element. In the assembled state, which is shown here, can have a contact area 308 electric current flow.

The first connector element 302 has an electrically conductive base body 318 on. The second connector element 304 is in the assembled state in the contact area 308 on the inner wall of the base body 318 pressed. This allows a current to flow between the electrically conductive second connector element 304 in the main body 318 of the first connector element 302 take place.

In order to prevent the live parts of the first connector element from being plugged together 202 can be touched is on the first connector element 302 a contact protection element 316 arranged. The contact protection element 316 is made of an electrically non-conductive material. In cooperation with a plastic housing (not visible in the figure), the contact protection element prevents 316 that objects that have larger dimensions than a defined test finger can come into contact with the live parts.

According to the present invention, the connector system comprises 300 a cooling device 314 for the removal of heat that is generated when an electrical current flows.

In particular, the cooling device 314 a cooling channel through a hollow pipe 320 is formed. The hollow pipe 320 is in a bearing element 322 held. This is the bearing element 322 according to the 6th and 7th embodiment shown by an area 330 with reduced cross-section, the one groove 324 for holding the hollow pipe 320 trains. The area 330 with a reduced cross-section extends in the axial direction far enough that the hollow conduit 320 several times around the bearing element 322 can be wound. This creates the thermally conductive transition between the base body 318 and the cooling duct is enlarged compared to the first embodiment, thereby increasing the heat dissipation efficiency. In that the storage of the hollow pipe 320 integral with the main body 318 is formed, a much more intimate, thermally conductive contact with the cooling fluid can be established and the thermal management can be further improved as a result. In addition, there is no need to assemble a separate bearing element designed, for example, as a sleeve.

As well as with regard to the 1 until 5 is described, the hollow pipe 320 a coolant flows through it during operation. For example, it can be a cooling fluid, and in particular a cooling liquid. Due to the heat-conducting contact of the hollow pipe 320 with the main body 318 at a relatively small distance from the contact area 308 can do that through the hollow pipe 320 guided coolants efficiently remove the heat generated. The cooling fluid can for example be connected to the cooling fluid circuit of a motor vehicle.

In the third embodiment shown, there must be electrical insulation between the cooling fluid and the base body 318 of the first connector element 302 ensure the material of the hollow pipe 320 be at least partially electrically insulating. For example, the hollow pipe 320 made of a plastic such as silicone. Other possible materials are polytetrafluoroethylene (PTFE), polyethylene (PE) or polypropylene (PP) can be used. Of course, there are also composite hoses, which, for. B. are reinforced by deposits of metal, fiberglass or textile braids, in question.

the 6th and 7th show that the hollow pipe 320 several times around the body 318 is performed to form a plurality of turns. Of course, only a single turn (similar to the 1 until 3 shown).

List of reference symbols

100, 200, 300

Connector system

102, 202, 302

First connector element

104, 204, 304

Second connector element; Mating connector element

106

Arrows for current flow

108, 208, 308

Contact area

114, 214, 314

Cooling device

116, 216, 316

Contact protection element

118, 218, 318

Base body of the first connector element

120, 220, 320

Hollow pipe

122, 222, 322

Bearing element

124, 224

Groove

126

Cooling fluid

128, 228, 328

Pin-shaped contact unit

130, 330

Area with reduced cross-section

132

Housing element

Claims (15)

Cooling device for a connector element (102), the cooling device (114) comprising: a cooling channel through which a cooling fluid (126) can flow during operation, and a bearing element (122) that holds the cooling channel, wherein the cooling channel is a component separate from the bearing element and has the shape of at least one hollow conduit (120) which surrounds the bearing element (122) at least in part of a circumference of the bearing element (122). Cooling device after Claim 1 , wherein the hollow line (120) engages around the bearing element (122) in a plurality of turns. Cooling device after Claim 1 or 2 , wherein the hollow conduit (120) comprises an electrically conductive material. Cooling device according to one of the preceding claims, wherein the bearing element (122) is at least partially made of an electrically insulating material. Cooling device according to one of the Claims 1 until 3 , wherein the bearing element (322) is designed as an integral part of a base body (318) of the connector element (302). Cooling device after Claim 5 wherein the hollow conduit (120) is at least partially electrically non-conductive. Cooling device according to one of the Claims 1 until 4th , wherein the bearing element (122) has a tubular shape and the hollow line (120), which forms the cooling channel, is held in a radially circumferential groove (124). Cooling device according to one of the preceding claims, wherein the hollow line (120) is at least partially made of copper or silicone. Connector element with an electrically conductive base body (118) and a cooling device (114) according to one of the preceding claims, wherein the bearing element (122) at least partially surrounds the base body (118) so that the cooling channel is in heat-conducting connection with the base body. Connector system with a first connector element (102) and a matching second connector element (104), wherein the first and the second connector element (102, 104) can be connected to one another in an electrically conductive manner and at least one of the connector elements (102, 104) has a cooling device (114) one of the Claims 1 until 8th having. A method for installing a high-voltage connector element (100), the method comprising the following steps: Providing a base body (118) with a bearing element (122); Attachment of a cooling channel which is held by the bearing element (122), wherein the cooling channel is a component separate from the bearing element and has the shape of a hollow conduit (120) which the bearing element (122) at least in part of a circumference of the bearing element (122 ) encompasses. Procedure according to Claim 11 , wherein the bearing element (122) has a sleeve-shaped sleeve which is pushed onto the base body (118). Procedure according to Claim 11 , wherein the bearing element (322) is formed by a receptacle (330) which is designed as an integral part of the base body (318) of the connector element (302). Method according to one of the Claims 11 until 13th wherein the step of attaching the cooling channel comprises winding around the bearing element (122) with at least one turn of the hollow conduit (120). Method according to one of the Claims 11 until 14th , further comprising the step of connecting the hollow conduit (120) to a cooling circuit.

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